‘Three Phase Separator Trainer - | Student Exercise Manual Training Sub Topi Gravity Separation OBJECTIVES Key Training Tople Objectives To learn basic principles of operation of a separator + To understand the effect on the separation process of varying operating conditions such as; flow characteristics, flow composition, and residence time inside the separator vessel + Identity and observe several flow measurement technologies + To understand separation dynamics - ollater/gas ratios and residence time inside the separator vessel Leeming Objectives Start up a three-phase separator and associated blending equipment + Adjust the process variables and operate at steady-state conditions + Use process measurements to compute mass balances around the separator system + Modify the ratio of ol to gas to water in the feed stream and observe the impact (on separation. + Describe and calculate separator residence time + Shut down the horizontal 3 phase separator unt Leaming Outcome ‘When students complete this laboratory exercise they will be able to start, operate and shut down a three phase separator demonstrator using manual control. They will learn the effect of various process variables in a three-phase separation operation, and be able to compute mass balance equations around the 3 phase separator unt. Safety ‘+ Process Fluids — water, air and refined oll (see MSDS). Low hazard; avoid prolonged skin exposure to oil + Process Conditions — low pressure and ambient temperature, No significant hazard, © 2010-2012 DatbyTech Training Equipment Inc Page tof 11Horizontal Taree - Phase Separator Demonstrator ‘Student Exercises Manual APPLICATION Overview When crude oils produced from the reservoir, itis typically a combination of gaseous {and liquid hydrocarbons mixed with water. The initial step of separation isto allow these fluids to slow down in a large vessel so that gravity can separate them. Water hhas the highest density and will settle to the bottom. Oil will float on the water, and any {ga wil fil the remaining space at the top. These three streams are then sent ‘Separately for further processing. If the product isin the separation process for enough time (sufficient residence time). the separation can be quite complete. if the velocity is, high and creates a shorter residence time, some liquid droplets (mist) may remain in the {988 stream, or an oillwater emulsion may occur in one or both ofthe liquid streams. Conventional Separators: Description Conventional separators are used in almost every type of field and plant gas. processing. They are used in the field to separate gases from liquids (and different liquids from each other). These liquids include water, hydrocarbon liquids, and crude cil. Separators come in two basic designs, vertical and horizontal. This refers to the orientation of the long axis of the vessel. In general, vetical vessels are used where the volume of liquid is small compared to the volume of gas. Horizontal vessels are sed when the reverse is the case. Conventional Separator Internal Design Cilfield phase separators, regardless oftheir shape or size, should include a primary or initial separation section, a secondary or gravity setting section, a mist extraction or coalescing section, and a liquid collecting section Primary or Initial Separation Section ‘The primary section is used to collect the majority of the liquid in the inlet stream. As the fluid mixture enters the vessel, a diverter baffle directs the flow to take advantage of the maximum available vessel volume. An abrupt change of direction is used to throw the major portion of entrained liquid outwards from the gas stream. Liquid Collecting Section “The lower section acts as a receiver for all liquid removed from the gas. The liquid section has a surge volume over the normal level of collected liquid, ‘Secondary or Gravity Settling Section ‘This section is normally designed to use the force of gravity. It consists of a portion of the vessel through which the fluids move at a relatively low velocity, Mist Extraction or Coalescing Section ‘The mist extractor removes the very small droplets of liquid in one final separation before the gas leaves the vessel. © 2010-2012 DarbyTosh’ ining Equipment In. Page 2of tiHorzonal Tree - Phase Separator Demonstrator ‘Suident Exercises Manuat Separator Design Characteristics A property designed separator essentially cleanly separates free gases from the free hydrocarbon liquids. If these functions are to be accomplished, the basic separator must have the following characteristics: Be constructed with adequate strength to withstand the required working pressure. 4. Control the well stream flow as it enters the vessel. 2. Provide adequate space for the accumulation of liquids, 3. Intemals arranged so as to provide minimum pressure drop. 4. Minimize turbulence in the gas section ofthe separator (and reduce the velocity of the gas stream). Control the accumulation of froths and foams inthe vessel 6. Eliminate re-entrainment ofthe separated gas and liquid. 7. Provide an outlet for gazes with ouitable controls to maintain preset operating pressure, 8 Provide outlets for liquids, with suitable liquid-level controls. HORIZONTAL 3 PHASE SEPARATOR DEMONSTRATOR Figure 1: Three-Phase Separator Demonstrator Description “The horizontal three phase separator demonstration apparatus is a small scale vessel that performs continuous separation of a mixture of ol, air and water. The primary separation operation for crude oll occurs when the crude stream flows thrcugh a vessel (© 2010-2042 DerbyTech Training Equipment In. Page Sof 11Horizontal Three - Phase Separator Demonstrator ‘Student Exercises Manual Of sufficient capacity to allow gravity separation of the gas, liquid hydrecarbon and water phases. This trainer includes a see-through horizontal primary separator vessel. The process has no instrumentation and is intended to demonstrate oilfield separation principles with basic visual / manual operation. ‘This demonstrator shows the process of separating a stream of simulated crude oil into its respective components: air, water and oil. To ensure safe operating practice ofthis ‘demonstrator, air is used to represent the gas phase and refined oil is used for the oil phase. Salt water (with normal table salt NaCl) is used to reduce emuisions and the ‘growth of bacteria, EQUIPMENT AND PROCESS HIGHLIGHTS Simulated Crude Oil Blender To simulate a crude oil stream, the blending unit causes the air, oil and water to mix together upstream of the separation. The flow rate of each process fuid is variable over a fairly wide range using the metering valves on the process outlet streams. By Independently controling the three feed rates, gas/oillwater rato is variable over a wide range. Air Blower ‘An air blower located on the lower shelf supplies the air stream, The blower delivers a high flow rate of low-pressure air tothe blending unt (0-40 fiminute @ 0-1.5 psi). The air flow rate is controlled by adjusting the air metering valve on the blower outlet line Pumps ‘Separate oil and water pumps are located on the lower shelf of the demonstrator. The pumps are capable of delivering between 0 and 10 litres/minute @ 0-7 psi (approximate values). The oll and water flow rates are controlled independently by adjusting the respective metering valves on the pump outlet lines. Separation Unit ‘The mixed stream (simulated crude ai) enters the separator through the vessel inlet ‘Air, representing the gas phase, leaves through a discharge line located on top ofthe ‘separator vessel. In this demonstrator, the aris discharged tothe atmosphere in the oil storage tank to capture any overflow. Normally this gas stream would go for further processing. Water and ol are discharged through lines exiting the bottom of the ‘separator vessel and are recycled into the system for continuous use. Primary or Initial Separation Section ‘The primary separation section is used to collect the majority ofthe liquid inthe inlet ‘stream, As the crude oil mixture enters the vessel, a diverter baffle ditects the flow to take advantage of the maximum available vessel volume. An abrupt change of direction is used to throw the major portion of entrained liquid outwards from the gas stream, The gas stream changes direction more readily than any liquid droplets that may be ©2010-2012 DarbyTech Training Equipment i. Page 4of 11Horizontal Troe - Phase Separator Demonstrator ‘Student Exercises Manual ‘entrained in the gas which results in the liquids collecting together in the bottom of the ‘separator vessel ‘Secondary or Gravity Settling Section ‘This lower section of the separator uses the force of gravity and the different fuid density properties to separate the oil and water streams. When the liquids are slowed ‘down in this section, the oll floats up to the top of the water. In this portion of the separator vessel, the fluids must move at a low velocity to allow enough time {the residence time) forthe fluids to separate. Mist Extraction or Coalescing Section “The mist extractor removes the very small droplets of liquid in one final separation before the gas leaves the vessel. This is to ensure that no entrained liquid droplets are allowed to pass through the separator in the gas stream. The extractor is a fine wire ‘mesh that causes the gas stream to change directions rapidly as it exits the separator vessel. Any entrained liquid droplets a Service Drain In addition to the oil and water process outlet lines, the separator vessel is equipped «with a drain line to allow the operator to drain any fluids from the separator for ‘maintenance purposes. Process Instrumentation ‘The horizontal separator demonstrator unit uses several flow meters (of different types to demonstrate the different technologies available) to measure the process flows in the Unit. These measurements can be used to compute mass-balance operations for the ‘separator, Tag# | Instrument Type Description ‘Averaging Simuteed [Ft | Phot gauge) Air flow rate into blender Gute Ol [rz [Gear Gil flow rate into blender FL3__| turine ‘Wale flow rate into blender ‘Separator | F4 | Ultrasonic (Transit Time) | Oil flow rate out of separator Outets _[FI-5 [Ultrasonic (Transit Time) | Water flow rate out of separator (© 2010-2012 DaroyTech Training Equipment ic aga 5 of 11Horizontal Tiree - Phase Separator Demonstrator Student Exercises Manual Process Specifications Highlights Control Imperial Units. 1 Units AIR | Variable | Oto 10.cfm | 0~1.5 psi| 0 to 0.30 min | 0-10 kPa OIL | Variable |Oto2USGPM| 0-10 psi | Oto8imin | 0-70 kPa WATER | Variable | 010 2USGPM| 0-10 psi] Oto8umin |0-70kPa LABORATORY EXERCISE PROCEDURES The equipment will be started using the startup procedure. Experimental procedures will be carried out, and then the equipment will be shutdown, Operating Procedure Pre-Start Up Procedure 1, Ensure that the separator gas discharge pipe is never restricted. 2. Check that the cartis level. If not, use shims or move to a level section of floor. lat any time the operation is getting out of control and overflow is imminent, turn OFF the pumps and blower switches and begin the start-up procedures again. Separator Startup and Familiarization Procedure 1. Trace flow lines and familiarize yourself with the equipment and controls. Refer to the process flow diagram supplied. 2. Ensure that level T-11 and T-12 are within the normal operating level with water ‘and oil, Never start the system with fluid volume below the MINIMUM or ‘above the MAXIMUM mark in each tank. Note that the water tank may have a layer of ol floating on top. If the level is high, it will be necessary to bail most of the oil back into the oll tank, 3, CLOSE the service drain valve on Vessel V-11 if itis open. a, Ifthe service drain was open and the separator vessel is empty, continue to step #4 to fl the separator vessel with water. b. Ifthe separator vessel contains oil and water (and the water level is within ‘1m (1/2 Inch) from the top of the water weir), skip step # 4 and continue to step #5. «. Ifthe separator vessel contains only water (and the water level is within 1 ‘cm of the top of the water weir), skip step #4 and continue to step # 5. To ensure that no oll s carried over with the water during start-up, its important that the separator vessel i fled with water before any oil is pumped into the vessel. If lis introduced before a proper water level has been reached, cil wll ©2010-2012 DarbyTech Training Equipment ns. Page 6of 11Horzontal Tree - Phase Soparator Demonstrator ‘Student Exercises Manuat carry-over into the water side of the separator and collect on the surface of the water in the water storage tank. Starting the blower and the water pump only, fill the separator vessel with water until the water is 1 cm (1/2 inch) below the top of the water weir. This will ensure that oil does not flow below the oil collecting section and into the water collecting section, Once the vessel has been filled, stop the water pump and blower and close all inlet valves. 5. Manually test al the control valves to ensure they are fully operational, PLACE the valves in the folowing position for inital start-up. air supply valve at 50% ‘water supply valve at 25% open oil supply valve at 25% open. ‘water dump valve 25% open . oil dump valve 25% open 6, START the Blower B-11 7. START the Water Pump P-12. Observe the inlet stream entering the separator and adjust the water supply valve if appropriate. 8, START the Oil Pump P-11. Observe the inlet stream entering the separator and adjust the oll supply valves if appropriate. 9. PLACE the Oil and Water Discharge Valves to about 25% open. As level begins to buildin the separator, adjust the valves to achieve steady-state flow. NOTE: Whenever adjusting the valves, do so in small stops to avoid over-filing or emptying the separator vessel completely. LAB EXERCISES (Oparate the separator unit using various flow rates of ar, water and oil, achieving steady-state conditions between all setpoint changes. Be sure to observe and record ‘separation conditions (qualitatively) and process flow rates (using supplied flow meters) at the various flow conditions selected, Establish steady state after each supply valve sting change. Table 1 — Data Table ‘Crude Oil Blender (inlet) Flows ‘Separator Outlet Flows Fit FIZ Fa Fla FS. Run | Air Flow Rate | Oil Flow Rate | Water Flow Rate | Oll Flow Rate | Water Flow Rate (© 2010-2012 DarbyTech Training Equipment nc Page TolitHorizontal Thre - Phase Separator Demonstrator ‘Student Exercises Manual NOTE: At high air flow rates, significant emulsion formation can occur. Under these conditions, skim oil frequently from the water tank back into the oil tank. 1 2 3 Record the air, water and oil supply valve positions and flow rates for each run. Wait 5 to 10 minutes after each supply flow rate adjustment. Monitor levels continuously and adjust discharge valves as required to achieve steady state conditions, Record your observations about the varying flow rates and quality of separation SEPARATOR SHUT-DOWN PROCEDURE ‘Shut OFF the Oil Pump P-11 and FULLY CLOSE the Oil Supoly Valve. ‘Once the oil has been transferred over the separator weir, PLACE the Discharge Valve in the fully open position, ‘Shut OFF the Water Pump P-12 and FULLY CLOSE the Water Supply Valve. Place the water discharge valve in the fully open position. ‘The oil and water in the in the gravity settling portion of the separator should be left in the unit during periods of inactivity less than one month. The service {drain should never be opened unless you are specifically instructed to do 0 by the instructor. ‘Shut DOWN the Air Blower B-11, Unplug the unit and secure the cord to the cart. REPORT Describe the operating conditions where emulsions occur. Describe the quality ofthe separation process with varying flow rates. Calculate a mass balance for the separator. Discuss any discrepancies in the mass balance calculations. ‘What isthe function of the inlet diverter and mist extractor? ‘What factors have an effect on separation quality? {© 2010-2012 DarbyTech Training Equipment inc Page Bol 14Horizontal Three - Phase Saparator Domonstator Student Exercises Manual DarbyTech Training Equipment inc. Texas A 6M Universi Horizontal Separator Damo PFD PIRES tebe _MIS-[ ONCE [ ev] © 10.2042 DarbyTech Training Equipment ine, Page 10 of44